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Hopper Loaders with/without Sight Glasses i SCC 2-Pump 20-Station Controllers Part Number: 882.00251.0 0 Bulletin Number: CV3-630 Effective: 10/25/05 Write Down Your Serial Numbers Here For Future Reference: _________________________ _________________________ _________________________ _________________________ _________________________ ____________[...]

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Hopper Loaders with/without Sight Glasses ii Shipping Information Unpacking and Inspection You should inspect your equipm ent for possible shipping damage. Thoroughl y check the equipment for any damage that m ight have occu rred in transit, such as broken or loose wiring and components, loose hardware and mounting screws, etc. In the Event of Ship[...]

2-Pump 20-Station Controllers iii Credit Returns Prior to the return of any material, authoriz ation must be given by the manufacturer. A RMS number will be assigned for the equipment to be returned. Reason for requesting the return must be given. All returned material purchased from the manufacturer is subject to 15% ($75.00 minimum) restocking ch[...]

Hopper Loaders with/without Sight Glasses iv Table of Contents[...]

Hopper Loaders with/without Sight Glasses 1 CHAPTER 1: SAFETY ................................................................ 3 1-1 How to Use This Manual ............................................................................................. 3 Safety Symbols Used in this Manual ...............................................................[...]

Hopper Loaders with/without Sight Glasses 2 Enabling and Disabling Stations and Pumps..................................................... 303 Starting and Stopping the System ..................................................................... 313 Reviewing and Adjusting Basic Station Settings ............................................... 314 N[...]

2-Pump 20-Station Controllers 3 Chapter 1: Safety 1-1 How to Use This Manual Use this manual as a guide and reference for installing, operating, and maintaining your equipment. The purpose is to assist you in a pplying efficient, proven techniques that enhance equipment productivity. This manual covers only light corrective main tenance. No other m[...]

Hopper Loaders with/without Sight Glasses 4 Controller Safety Tags 1-2 Warnings and Precautions Our equipment is designed to provide safe and reliable operation when installed and operated within design specifications, following national a nd local safety codes. This may include, but is not limited to OSHA, NEC, CSA, SPI, and any other local, natio[...]

2-Pump 20-Station Controllers 5 1-3 Safety Device s and Interlocks This section includes information on safety devices and procedures that are inherent to the Controller. This manual is not intended to s upersede or alter safety standards established by the user of this equipment. Instead, the materi al contained in this section is recommended to s[...]

Hopper Loaders with/without Sight Glasses 6 1-4 Responsibility These machines are constructed for maximum operator safety when used under standard operating conditions and when recommended inst ructions are followed in the maintenance and operation of the machine. All personnel engaged in the use of the machin e should become familiar with its oper[...]

2-Pump 20-Station Controllers 7 Learn and always use safe operation. Cooperate with co-workers to promote safe practices. Immediately report any potentially dangerous s ituation to your supervisor or app ropriate person. Maintenance Responsibility Proper maintenance is essential to safety. If you are a maintenance worker, you must make safety a pri[...]

2 –Pump 20-Station Controllers Functional Description 8 of 51 Chapter 2: Functional Description 2-1 Models Covered in This Manual This manual provides operation, installation, and m aintenance instructions for 2-Pump, 20- Station Conveying Controllers. Model numbers are listed on the serial tag. Make sure you know the model and serial number of y[...]

2–Pump 20-Station Controllers Functional Description 9 of 51 • Non-fused disconnect switch, lockable • Branch circuit fusing • Fully accessible NEMA 12-styl e electrical control enclosure Controller Features • Allen-Bradley PLC with 6” color touch screen display • Monitors Station status and Pump status • Allows operator to transfer[...]

Hopper Loaders with/without Sight Glasses 10 Chapter 3: Inst allation 3-1 Uncrating 2-Pump, 20-Station Controllers are shipped mounted on a skid, enclosed in a pla stic wrapper, and contained in a cardboard box. 1. Pry the crating away from the skid. Note: Remove the nails holding the box to the skid and lift the box off carefully; avoiding staples[...]

2–Pump 20-Station Controllers Installation 11 of 51 Figure 1: 2 Pump 20 Station Controller with 6" Display 24 ” 30 ” 6 ” * De p th dimension is 12”[...]

Hopper Loaders with/without Sight Glasses 12 XXX CONTROL PA NEL Model No. XXX2-2 0 Serial No. 31K01 82 Control Volta g e 24VDC 60 115 1 3-3 Controller Identification (Serial Number) Tag (Located on the side of the controller box) Street Address Town, State, Zip Code Telephone Number Fax Number Vol t Hz Ph[...]

2–Pump 20-Station Controllers Installation 13 of 51 3-4 Electrical Connections Refer to local electrical codes, the schematic and connection diagrams supplied with this unit and the serial tag for wiring considerations . Run all wiring in c onduit if codes require it. Making Control Panel Power Drop Wiring Connections Hardwire the input power at [...]

Hopper Loaders with/without Sight Glasses 14 5. On 115 VAC control voltage systems, run a common hot (115 VAC) wire and a common neutral wire from the controller to each pump package in the system. On 24 VDC control voltage systems, run a common +24 VDC wire and a common 0 (zero) VDC wire from the controller to each pump package in the system. Note[...]

2–Pump 20-Station Controllers Installation 15 of 51 Figure 3: “Menu” Screen 2. At the “Menu” screen, (Figure 3), touch the System Setup button. The “System Setup” screen opens. Figure 4: “System Setup” Screen Before Setup Stati ons 19-20 3. At the “System Setup” screen, (Figure 4), touch Stations Present . A keypad pops up. 4.[...]

Hopper Loaders with/without Sight Glasses 16 6. Enter the total number of pumps (1-2) to be controlled b y the system. Use (Backspace Key) to erase any mistakes. Use (Enter Key) to enter the value. The keypad disappears, and the new setting appears under Pumps Present . Setting Up Alarm Duration When an alarm occurs, a horn sounds and a st robe lig[...]

2–Pump 20-Station Controllers Installation 17 of 51 5. Enter the number of minutes (between 0 and 99) that you want the horn to stay off. If you want the horn to stay on as long as the alarm persists, leave the setting at 0. If you want the horn to stay off until a new al arm occurs, enter 99 in the keypad. Use (Backspace Key) to erase any mistak[...]

Hopper Loaders with/without Sight Glasses 18 Setting Up Stations Before starting the system, you must define several settings for each station, such as which pump conveys material to it. This section first discusses how to use the controller’s menu system to configure stations. The table on pa ges 40–41 discusses the individual choices. Setting[...]

2–Pump 20-Station Controllers Installation 19 of 51 Figure 8: “Station Setup” Screen 4. On the “Station Setup” screen (Figure 8), adjust settings as required. Touching any box that appears in red (for “disabled”) toggles it to green (for “enabled”), and vice versa. Touching any white box gives you a keypad to enter a new value. To[...]

Hopper Loaders with/without Sight Glasses 20 Figure 9: “Station Copy” Screen Last Station 19 Last Station 20 Follow the directions below to copy settings to one other station, a range of stations, or all stations: Copying to One Other Station: 1. On the “Station Copy” screen (Figure 8), touch the gray Copy to Station button. The keypad pops[...]

2–Pump 20-Station Controllers Installation 21 of 51 value. The keypad disappears, and the “Station Copy” screen shows the station number you entered under Last Station . 5. Touch the green Copy to Range of Stations button. Complete briefly appears on the screen. 6. As appropriate, either continue co pying to other stations, or touch Return to[...]

Hopper Loaders with/without Sight Glasses 22 Figure 11: Pump Setup Screen B low back 5 Puls es 3. Adjust settings as required. Touching any box that appears in red (for “disabled”) toggles it to green (for “enabled”), and vice versa. Touching any box that appears in white gives you a keypad to enter a new value. See page 422 for details on [...]

2–Pump 20-Station Controllers Installation 23 of 51 Figure 12: Pump Copy Screen Last Pum p 2 Last Pum p 2 Copy to Pu mp 2 Follow the directions below to copy settings to one other station, a range of stations, or all stations: • Copying to One Other Pump: 1. On the “Pump Copy” screen (Figure 12), touch the gray Copy to Pump button. The keyp[...]

Hopper Loaders with/without Sight Glasses 24 3. Figure 12) touch the gray First Pump button. The keypad pops up. 4. Enter the pump number for the lower end of the range you are copying to. Use (Backspace Key) to erase any mistakes. Use (Enter Key) to enter the value. The keypad disappears, and the “Pump Copy” screen shows the pump number you en[...]

2–Pump 20-Station Controllers Installation 25 of 51 the options installed, the screen may also enable the operator to adjust the mix percentage for a remote proportioning valv e, review the last purge time and purge valve, and set the intended material line for material proofing). Entering the setup password will give the user access to all funct[...]

Hopper Loaders with/without Sight Glasses 26 to enter the value. The keypad disappears, and the “System Setup” screen shows the new setting. 3-6 Initial Startup Once you have finished all the setup described above, you are ready to start the system. To start your system, complete the following steps. 1. At any screen, touch Menu on the right si[...]

2–Pump 20-Station Controllers Operation 27 of 51 Chapter 4: Operation 4-1 Overview Your 2-pump, 20-station controller electrically contro ls valves and solenoids to convey material from a central location to individual stations as needed. The controller senses demands for material at the stations and r esponds to the demands in a timely fashion. [...]

Hopper Loaders with/without Sight Glasses 28 4. When you are finished review ing the information, touch Return . The “Help Menu” screen opens. 5. Touch Menu to return to the “Menu” screen. The following table explains the status re presented by each color at the “Station Status” screen. Color Label Description Gray outline Offline Stati[...]

2–Pump 20-Station Controllers Operation 29 of 51 1. Touch Menu . The “Menu” screen appears. 2. Touch Help . The “Help Menu” screen appears. 3. Touch Pump States . The “Pump Symbols Help” screen appears, explaining the status represented by each color. 4. When you are finished review ing the information, touch Return . The “Help Menu[...]

Hopper Loaders with/without Sight Glasses 30 Enter the four-digit password (including any lead ing zeros). For example, if the password is 1, enter 0001 . Each digit appears as an “ X ” as you touch it. When you touch the fourth digit, t he controller carries out your request. For example, it enables or disables the requested pump or station, o[...]

2–Pump 20-Station Controllers Operation 31 of 51 Starting and Stopping the System WARNING! In an emergency, you can use the power switch at the controller cabinet if a password is required to stop the system and you do not know the password. Note: Normally, all the stations and pumps you want to use should be enabled before you start the system. [...]

Hopper Loaders with/without Sight Glasses 32 Navigating Among the Station Operator Screens The controls in the upper right-hand corner of the screen enable you to m ove among the “Station Operator” screens: • To display the screen for the next lower-num bered station (for exam ple, to move from the screen for Station 15 to the screen for Stat[...]

2–Pump 20-Station Controllers Operation 33 of 51 Activating and Stopping Priority Convey for a Station Note: Before activating priority convey, make sure that all other stations using the same pump have adequate material in reserve to c ontinue operation. No material will be conveyed to these stations during priority convey. If you want the contr[...]

Hopper Loaders with/without Sight Glasses 34 Figure 17: Pump Setup Screen The box labeled x Hours Resettable shows the running time since the last reset. The box labeled x Hours shows total running time. To reset the resettable meter, touch Hour Meter Reset . The time above Hours Resettable changes to 0. Transferring Stations to a Standby Pump If a[...]

2–Pump 20-Station Controllers Operation 35 of 51 Figure 18: “Transfer To Standby Pump” Screen 6. Touch Source Pump. The keypad pops up. 7. Enter the number of the failed pump. Use (Backspace Key) to erase any mistakes. Use (Enter Key) to enter the value. The number appears under Source Pump . 8. Touch Standby Pump . The keypad pops up. 9. Ent[...]

Hopper Loaders with/without Sight Glasses 36 If these conditions are not all met, erro r messages appear on the screen instead of a Transfer to Standby Pump button. If you get an error message, first check to make sure that you have en tered the correct numbers and reenter if necessary. If another error occurs, see the Standby Pump Errors section b[...]

2–Pump 20-Station Controllers Operation 37 of 51 Figure 20: Alarm Log Screen To scroll up and down through the list, t ouch ▲ and ▼ at the bottom of the list. Silencing Alarms Whenever a new alarm occurs, your controller sounds the horn and turns on t he strobe light at each central alarm. Touch Alarm Silence on the alarm message banner that [...]

Hopper Loaders with/without Sight Glasses 38 Chapter 5: Restoring a Lost or Corrupt Program 5-1 Corrective Maintenance PLC Memory Module A PLC memory module (ACS Part# A0567138) loaded with the appropriate program for the system purchased is provided as both a backup in the event of a catastrophic failure and as a means to upgrade the PLC program. [...]

2–Pump 20-Station Controllers Restoring a Lost or Corrupt Program 39 of 51 2. Insert the memory module. Note: this step can be preformed while the unit is powered, however care should be taken not to contact any wiring within the control cabinet. 3. Cycle power to the control cabinet allowing approximately 30 seconds for the DC power supply (if p[...]

Hopper Loaders with/without Sight Glasses 40 Chapter 6: Configurable Settings/Default s This section describes the proper setup of the 2 pump, 20-station control s ystem parameters. These parameters are operator changeable; however, these items sh ould require setup only during the initial installation. Only authorized personnel should cha nge them[...]

2–Pump 20-Station Controllers Confi gurable Settings/Defaults 41 of 51 Name Description Options Default Alarm Options No convey When this option is enabled, the controller issues a “no convey” alarm if it has repeatedly attempted to convey material to the station but the flapper never opened during the dump delay. (The number of attempts is c[...]

Hopper Loaders with/without Sight Glasses 42 6-2 Pump Setup - Factory Presets Several of the items in this screen are not setup options but are instead intended for use during operation. These items (hour meter and transferring stations to a standby pump) are described in Chapter 4, which cover operation procedures. Name Description Options Default[...]

2–Pump 20-Station Controllers Troubleshooting 43 of 51 Chapter 7: T roubleshooting 7-1 General Troubleshooting Problem Possible Cause Solution The control pa nel is not turned on. Turn on the contr ol panel. The external disconnect (recommende d) in the dedicated circuit is open (off). Close the switch (on). Fuse/circuit breaker in the power drop[...]

Hopper Loaders with/without Sight Glasses 44 7-2 Alarms The format for all station alarms is “Station n [alarm text].” The format for all pump alarms is “Pump n [alarm text].” Any alarm that does not start with “Station” or “Pump” is a system alarm. The following tables list all alarms alphabetica lly, together with possible causes.[...]

2–Pump 20-Station Controllers Appendix 45 of 51 Chapter 8: Appendix 8-1 Warranty The manufacturer warrants all equipment manufactured by it to be free from defects in workmanship and material when used un der recommended conditions. The company’s obligation is limited to repair or replace FOB th e factory any parts that are returned prepaid wit[...]

Hopper Loaders with/without Sight Glasses 46 8-3 Spare Parts List AC Voltage Quantity Part Number Description 1 A0563932 2.1A Power Supply for touch screen 1 A0559862 Input Card 1 A0572817 Output Card 1 1 1 1 A0569858 A0565880 A0573717 A0573702 PLC.Base PLC CPU (request Pre-programmed) 6” Touch screen (Pre-programmed) Program, Memory Module, AC i[...]

2–Pump 20-Station Controllers Appendix 47 of 51 8-4 Technical Assistance (Contact Information) Parts Department Call toll-free 7am–5pm CST [ 800 ] 423- 3183 or call [ 630 ] 595-1060, Fax [630] 475-700 5 The ACS Customer Service Group w ill provide your compa ny with genuine OEM quality parts manufactured to engi neering design specific ations, [...]